Connection structure for a log wall

ABSTRACT

A connection structure for a log wall includes a plurality of logs extending horizontally in an axial direction and stacked vertically to form a wall, the logs each having an end face at one end thereof, the end faces of the logs being generally vertically aligned with each other and defining an edge surface of the wall; a plurality of connectors retained within the wall adjacent the edge surface of the wall; a plurality of fastener access passageways in the wall, each fastener access passageway extending between a respective connector and the edge surface of the wall; and a plurality of fasteners, each fastener extending through a respective fastener access passageway and having a first end coupled to a respective connector and a second end opposite the first end, the second end extending proud of the edge surface of the wall.

This application is a divisional of prior U.S. application Ser. No.10/372,854, filed Feb. 26, 2003, which is hereby incorporated herein byreference.

FIELD

This invention relates to construction systems for constructing logstructures such as houses, cabins, and the like, and more particularlyto connection structures for connecting, for example, logs to a post.

BACKGROUND

Homes or cabins built of logs are often considered desirable for theiraesthetics. However, constructing such log structures can present anumber of difficulties. For example, it can be difficult to providecorner connection of logs at an intersecting corner that is strong andweather tight, both at initial installation and after the log walls havesettled over time.

A known corner connection structure is disclosed in U.S. Pat. No.5,020,289 (Wrightman). The corner connection of Wrightman provides adovetail joint between the intersecting logs, and a pair of splineshaving a ‘figure-8’ cross-sectional profile. However, the structuralelements themselves leave seams through which the weather couldpenetrate. Caulking could be provided for weather-proofing, but caulkinghas a limited lifespan, and could work loose during natural settling andshrinkage of the logs. Alternatively, gaskets could be provided betweenthe mating faces of the dovetails, but gaskets can be relatively costlyand time-consuming to install.

Another corner connection structure is disclosed in U.S. Pat. No.4,353,191 (Schilbe). The corner connection structure of Schilbe has anobliquely disposed mortise provided adjacent the intersecting region oflogs at a corner, and a wooden locking section placed in the mortise.However, by providing the mortise adjacent the intersecting region,rather than within the intersecting region, the locking member isengaged only at its outer ends by the mortise, which may limit thestrength and support provided by the locking member. Furthermore,Schilbe does not address the natural settling of the logs that takesplace over time. The fit between the mortise and the locking member, astaught by Schilbe, must be sufficient to prevent horizontal movement ofthe logs relative to the locking member. However, such a tight fit wouldalso inhibit vertical movement of the logs relative to the lockingmember, which could result in gaps forming between the logs along theheight of the walls at the intersecting corner. The weather may thenpenetrate the corner structure, and moisture could collect within thelog structure, between the inside of the walls and the locking member.

Providing through-bolts at corners or at intermediate positions alongthe lengths of log walls can provide additional strength and support forthe walls. Known through-bolt devices are described in U.S. Pat. No.4,503,647 (Post) and U.S. Pat. No. 4,688,362 (Pedersen et al.). In bothof these references, the through-bolt devices include through-boltsextending along the height of the walls, and regular hex nuts at thelower end of the through-bolts for tightening the devices. These devicesrequire access to the hex nuts for wrenches or other tools whenassembling or adjusting the through-bolt devices. However, providingsuch access may be difficult, and may require, for example, fairly largeopenings cut into the lower sides of the walls. Specially cut panels maythen be required to conceal the openings.

It is often convenient in walls constructed of logs that two shorterlogs be joined end-to-end to span the length of the wall. A butt jointfor connecting logs end-to-end is disclosed in the patent to Wrightman,already noted above. The butt joint according to Wrightman has atwo-piece spline with semi-circular lobes on one face and opposingpassages on the opposite face. Spikes are driven into the passages toexpand the two-piece spline, and provide an interference fit between thelobes of the spline and matching recesses provided in the logs. Thisbutt joint is fairly complex and may be time consuming to assemble.Furthermore, the simultaneous alignment of the passageways and the lobeswithin the recesses may be difficult to achieve.

Another butt joint is disclosed in U.S. Pat. No. 4,279,108 (Collister,Jr.). The butt joint of Collister Jr. has plastic weather deflectorsinserted into a slot, which spans the seam between the adjacent endfaces of the logs to be joined. Compressible gasket strips are alsoprovided between the end faces of the adjacent logs. Since no structuraljoint element engages the logs in a transverse direction, it may bedifficult to ensure that the logs connected by this joint are in factlocked to inhibit longitudinal movement. Furthermore, since the gasketstrips are installed prior to fixing the logs together, the strips maybe damaged during positioning and assembly of the logs.

Openings are often desirable in log walls to accommodate windows, doors,and the like. It may be advantageous to provide special supportstructures at such openings to facilitate building the walls around theopening, and to provide a suitable mounting means for the structuralframing elements of the window or door to be subsequently installed. Aknown opening support structure is disclosed in U.S. Pat. No. 4,224,772(Bene et al.). Bene et al. discloses a connection member disposedbetween the log end faces at the opening and the frame member of awindow to be installed in the opening. The connection member is attachedto the logs by nails driven through slots in the connection member andinto the end grain of the logs, so that relative vertical movementbetween the connection member and the logs is possible. The frame memberof the window is in turn secured to the connection member. Using nailsdriven into the end grain of the logs may not, however, provide a securejoint because the nails may work loose as the fibers of the woodseparate. Furthermore, shrinkage of the logs over time may compromisethe strength of the support structure.

In building log walls, the logs themselves can be provided with aparticular profile to facilitate alignment of the logs duringconstruction and to increase the strength of the wall. In theabove-noted Wrightman patent, a log profile is disclosed in which thetongues and grooves are provided in the upper and lower surfaces of thelogs, respectively. The upper and lower surfaces of vertically adjacentlogs fit together, providing a seam across the width of the logs.However, at either side of the logs, the profile provides a generallyhorizontal seam portion which could collect moisture and causeassociated wood preservation difficulties.

Another log profile is disclosed in U.S. Pat. No. 3,440,784 (Onjukka).The profile taught by Onjukka has matching tongues and grooves in theupper and lower surfaces of vertically adjacent logs. However, noprovision is made for installing seals along the seam between adjacentlogs, at a point along the seam between the outer horizontal edges.Accordingly, the weather-proofing of the interface between adjacent logsmay be compromised, particularly as the logs shrink and settle overtime.

In some log structures having walls constructed of stacked horizontallogs, it can be advantageous to provide vertical posts at the corners ofintersecting walls, as well as at intermediate points along the lengthof a wall. A post-to-log connection structure can be provided forconnecting the end faces of the logs to a vertical surface along thepost. A known post-to-log connection structure is disclosed in U.S. Pat.No. 4,742,033 (Veech), wherein a vertical spline is inserted intocorresponding slots provided in the end faces of the logs and thesurface of the post. However, no adjustable fastening means is providedfor drawing the post and log ends snugly together.

SUMMARY

The following summary is intended to introduce the reader to thisspecification but not to define any invention. In general, thisspecification discusses one or more methods or apparatuses related toconstructing log structures. Aspects of the teaching provided herein bythe applicants include, but are not limited to, corner connectionstructures, through-bolt clamping apparatuses, logs with particular logprofiles, log support structures, exterior casing structures, butt-jointconnection structures, log connection structures, and joint sealingstructures.

Various apparatuses or processes are described herein to provide anexample of an embodiment of each claimed invention. No embodimentdescribed below limits any claimed invention and any claimed inventionmay cover processes or apparatuses that are not described below. Theclaimed inventions are not limited to apparatuses or processes havingall of the features of any one apparatus or process described below orto features common to multiple or all of the apparatuses describedbelow. It is possible that an apparatus or process described below isnot an embodiment of any claimed invention. The applicants, inventors orowners reserve all rights that they may have in any invention disclosedin an apparatus or process described below that is not claimed in thisdocument, for example the right to claim such an invention in acontinuing application and do not intend to abandon, disclaim ordedicate to the public any such invention by its disclosure in thisdocument.

According to one aspect, a connection structure for a log wall isprovided, the connection structure comprising: (a) a plurality of logsextending horizontally in an axial direction and stacked vertically toform a wall, the logs each having an end face at one end thereof, theend faces of the logs being generally vertically aligned with each otherand defining an edge surface of the wall; (b) a plurality of connectorsretained within the wall adjacent the edge surface of the wall; (c) aplurality of fastener access passageways in the wall, each fasteneraccess passageway extending between a respective connector and the edgesurface of the wall; and (d) a plurality of fasteners, each fastenerextending through a respective fastener access passageway and having afirst end coupled to a respective connector and a second end oppositethe first end, the second end extending proud of the edge surface of thewall.

In some embodiments, the connectors can extend between verticallyadjacent pairs of the plurality of logs, each pair of logs including arespective lower log and an upper log generally situated on top of thelower log, each connector having a connector body with a lower and anupper log engagement portion, each lower log engagement portion engagingthe respective lower log, and each upper log engagement portion engagingthe respective upper log.

In some embodiments, each respective lower log can comprise a topsurface and each respective upper log can comprise a bottom surfacegenerally facing the top surface of each respective lower log, each topsurface having an upper connector aperture extending therefrom and intothe respective lower log for receiving the lower log engagement portionof the respective connector, and each bottom surface having a lowerconnector aperture extending therefrom and into the respective upper logfor receiving the upper log engagement portion of the respectiveconnector.

In some embodiments, the fastener access passageway can comprise adepression in at least one of the top surfaces of the respective lowerlogs and the bottom surfaces of the respective upper logs, the at leastone depression extending from a respective connector aperture to arespective end face of the log. Each connector can be spaced axiallyapart from the edge surface to provide a load bearing portion of eachrespective log between the connectors and the end faces.

In some embodiments, the connection structure can include a plurality ofbrackets, each bracket coupled to a respective fastener adjacent thesecond end thereof. The connection structure can comprise a post coupledto the brackets and having a generally vertical joint face in abutmentwith the end faces of the logs, the fastener being adjustable tosecurely draw together the logs and the post. The post can have achannel in the joint face of the post, the channel extending verticallyalong the height of the post, and wherein the bracket is verticallyslidable within the channel. The channel can include a bracket housingportion spaced axially away from the joint face and a slot portionextending between the joint face and the bracket housing portion, thebracket being slidably retained in the bracket housing portion and thefastener extending through the slot portion. The housing portion cancomprise shoulders extending laterally outward from the slot portion,and the bracket can have laterally extending clamp arms that bearagainst the shoulders

According to another aspect, a connection structure is provided, thestructure comprising: (a) a plurality of horizontally extending,vertically stacked logs forming a wall, the logs defining an axialdirection along their lengths, the logs each having an end face at oneend thereof, the end faces of the logs being generally verticallyaligned with each other; (b) a post having a generally vertical jointface in abutment with the end faces of the logs; and (c) at least onelink assembly for coupling at least one of the logs to the post, eachlink assembly including a connector anchored in the at least one log anda bracket anchored in the post and coupled to the connector, the bracketbeing vertically slidable relative to the post.

In some embodiments, the link assembly can comprise a fastener extendingbetween the bracket and the connector. The fastener can be adjustablefor adjusting the spacing between the bracket and the connector.

In some embodiments, the connection structure can include a channel inthe joint face of the post, the channel extending vertically along theheight of the post, and the bracket being vertically slidable within thechannel. The channel can comprise a bracket housing portion spacedaxially away from the joint face and a slot portion extending betweenthe joint face and the bracket housing portion, the bracket beingslidably retained in the bracket housing portion and the fastenerextending through the slot portion. The housing portion can compriseshoulders extending laterally outward from the slot portion, and thebracket can include laterally extending clamp arms that bear against theshoulders. The clamp arms can comprise flange portions obliquely alignedrelative to each other, and the retaining shoulders can compriseobliquely aligned contact surfaces for providing generally flush contactwith the flange members of the bracket.

The fastener can comprise a bolt having a first end coupled to theconnector and a second end opposite the first end and coupled to thebracket. The connecter can have a cross bore extending generallyhorizontally through the connector and through which the fastenerextends, the cross bore having a counter-bored portion directed awayfrom the bracket, the head of the bolt being seated in the counter-boredportion. The bracket can comprise a threaded member for engaging thethreaded portion of the bolt, the threaded member being fixed againstrotation relative to the bracket, and the bracket being fixed againstrotation relative to the post.

According to another aspect, a connection structure for a log wall isprovided, the structure comprising: (a) a plurality of horizontallyextending, vertically stacked logs forming a wall, the logs defining anaxial direction along their lengths, the logs having generallyvertically aligned end faces at one end thereof; (b) a post having agenerally vertical joint face in abutment with the end faces of thelogs; (c) a plurality of connectors positioned in the wall adjacent thepost, each connector having a connector body with a lower and an upperlog engagement portion, each lower log engagement portion engaging arespective lower log in the wall, and each upper log engagement portionengaging a respective upper log in the wall, each upper log beingpositioned vertically above each lower log, respectively; (d) aplurality of brackets retained within the post, each bracket generallypositioned in horizontal registration with a respective connector; and(e) a plurality of fasteners, each fastener extending between arespective connector and bracket for coupling together the respectiveconnector and bracket.

According to another aspect, a connection structure for a log wallincludes a bracket coupled to a post, wherein the bracket is verticallyslidable relative to the post, a connector positioned within the walladjacent the post, a fastener access passageway extending through thewall between the bracket and the connector, and a fastener extendingthrough the fastener access passageway, wherein the fastener is coupledto the bracket and to the connector, and is adjustable to draw the logssnugly against the post.

The connector may have a connector body with lower and upper logengagement portions, wherein the lower engagement portion engages a login one course, and the upper engagement portion engages a log in acourse vertically above the log engaged by the lower log engagementportion.

The logs adjacent the post may have top surfaces provided with upperconnector apertures adapted to receive the lower log engagement portionsof the connectors, and bottom surfaces provided with lower connectorapertures adapted to receive the upper log engagement portions of theconnectors. The outer profiles of the connectors may be adapted toprovide interspersed areas of contact and areas of non-contact betweenthe outer surface of the connectors and the inner surface of theconnector apertures.

Each fastener may be a bolt having at opposite ends a head and athreaded portion, and the connectors may be provided with a generallyhorizontal bore shaped to engage with the head of the bolt. A hex nutmay be coupled with the threaded portion of the bolt, and a locking pinmay extend transversely from the nut and engage the bracket.

Opposed depressions may be provided in the top and bottom surfaces ofthe logs, the depressions adapted to cooperate to form the fasteneraccess passageways. The opposed depressions may be v-grooves. The postof the post-to-log connection structure may be provided with a generallyvertical channel abutting the logs, and the bracket may be verticallyslidable within the channel. The channel may have generally transverseretaining lips, and the bracket may have clamp arms in engagement withthe retaining lips.

The clamp arms of the brackets may be obliquely aligned flange members,wherein the spacing between the flange members converges from a widerspacing away from the connectors, to a narrower spacing nearer theconnectors. The retaining lips may have obliquely aligned contactsurfaces for providing generally flush contact with the flange membersof the bracket.

DESCRIPTION OF THE DRAWINGS

For a better understanding of the applicant's teaching and to show howit may be carried into effect, reference will now be made by way ofexample, to the accompanying drawings in which:

FIG. 1 is a perspective view of a portion of two intersecting wallshaving, in accordance with examples of the applicant's teaching, acorner connection structure, a through-bolt clamping apparatus, logswith a particular log profile, an opening support structure, an exteriorcasing structure, and a butt-joint connection structure;

FIG. 2 is a perspective view showing the corner connection structure ofFIG. 1 in greater detail;

FIG. 3 a is side view of a portion of a log used in the connectionstructure of FIG. 2;

FIG. 3 b is an end view of the portion of the log shown in FIG. 3 a;

FIG. 4 is an elevation view of the corner connection structure of FIG.1, in combination with a through-bolt clamping apparatus;

FIG. 5 is a top view of two logs of the corner connection structure ofFIG. 1;

FIG. 6 is an exploded view of the logs shown in FIG. 5;

FIG. 7 is an enlarged view of one of the logs shown in FIG. 6;

FIG. 8 shows the logs of the corner connection structure of FIG. 5 incombination with a corner spline according to the present invention;

FIG. 8 a is an enlarged view of a portion of FIG. 8;

FIG. 9 a is a perspective view of a corner spline according the presentinvention;

FIG. 9 b is a side view of the spline of FIG. 9 a;

FIG. 10 is an elevation view of an alternative embodiment of a cornerspline for use with a corner connection structure of the presentinvention;

FIG. 11 is a perspective view of an alternative embodiment of a cornerspline for use with a corner connection structure of the presentinvention;

FIG. 12 is an exploded view of the through-bolt clamping apparatus ofFIG. 4;

FIG. 13 is a top view of a corner spline shown in FIG. 12;

FIG. 14 is a bottom view of a lowermost log of the corner connectionstructure of FIG. 1;

FIG. 15 is an exploded view of an alternative embodiment of a portion ofthe apparatus of FIG. 12;

FIG. 16 is a portion of the elevation view of FIG. 4, in combinationwith the apparatus of FIG. 15;

FIG. 17 is a front elevation view of another embodiment of athrough-bolt clamping apparatus according to the present invention;

FIG. 18 is an exploded view of the apparatus of FIG. 17;

FIG. 19 is a side elevation view of the apparatus of FIG. 17;

FIG. 20 is an exploded view of an alternative embodiment of a portion ofthe apparatus of FIG. 17;

FIG. 21 is a front elevation view of FIG. 20 in combination with theapparatus of FIG. 17;

FIG. 22 is a cross-sectional view of the log profile of FIG. 1;

FIG. 23 is a cross-sectional view of one log of FIG. 22 stacked uponanother;

FIG. 24 is a cross-sectional view of an alternative embodiment of a logprofile according to the present invention;

FIG. 25 is a cross-sectional view of one log of FIG. 24 stacked uponanother;

FIG. 26 is a front elevation view of the wall opening support structureof FIG. 1;

FIG. 27 is a perspective view showing a portion of the structure of FIG.26 in further detail;

FIG. 28 a is a side view of a support block of FIG. 27;

FIG. 28 b is a side view of another support block of FIG. 27;

FIG. 29 is a perspective view of the structure of FIG. 26 showingfurther details;

FIG. 30 is a side elevation view in cross-section of a portion of thestructure of FIG. 26;

FIG. 31 is a top sectional view of a portion of the structure of FIG.26;

FIG. 32 is a top sectional view of a sub-jamb member of FIG. 29;

FIG. 33 is a front elevation view of the sub-jamb member of FIG. 32;

FIG. 34 is a perspective view showing further details of the openingsupport structure and exterior side casing structure of FIG. 1;

FIG. 35 is a cross-sectional view of a portion of the exterior sidecasing structure of FIG. 34;

FIG. 36 is a top view of the exterior casing structure of FIG. 34;

FIG. 37 is an exploded perspective view of the butt joint connectionstructure of FIG. 1;

FIG. 38 is a top view of portions of the butt joint connection structureof FIG. 1;

FIG. 39 is a top view of a spline of the butt joint connection structureof FIG. 1;

FIG. 40 is a top cross-sectional view of the butt joint connectionstructure of FIG. 1;

FIG. 41 is a section view of FIG. 40 taken along the line 41-41;

FIG. 42 is an exploded perspective view of an example of a connectionstructure according to the applicant's teaching;

FIG. 43 is an exploded view of a component of the of the connectionstructure of FIG. 42;

FIG. 44 is a top view of the connection structure of FIG. 42;

FIG. 45 is a perspective view of alternative seal assembly for use withthe present invention; and

FIG. 46 is a top view of the assembly of FIG. 45 shown in combinationwith a misaligned slot.

DETAILED DESCRIPTION

A corner connection structure according to the applicant's teaching isshown generally at 10 in FIG. 1. The corner connection structure 10 isprovided at a corner 12 where walls 14 a and 14 b intersect. The walls14 a and 14 b form part of a building such as, for example, but notlimited to, a home or cabin.

Referring to FIG. 2, the walls 14 a and 14 b are constructed ofgenerally horizontally extending logs 16 a and 16 b, respectively. Thewalls 14 a and 14 b are nonparallel, intersecting each other at thecorner 12. In the embodiment illustrated, the walls 14 a and 14 bintersect at approximately 90°. However, the angle of intersection atcorner 12 could be any angle, and it is to be appreciated that thecorner connection structure 10 could be used on walls having any angleof intersection, and also on walls meeting at a T-intersection.

The logs 16 a and 16 b of the walls 14 a and 14 b have ends 17 a and 17b which are proximate the corner 12. Adjacent the ends 17 a and 17 b,the logs 16 a and 16 b are provided with overlap portions 18 a and 18 b,respectively, which overlap each other in an alternating interlacedarrangement at the corner 12. The logs 16 a, 16 b have non-overlappingportions 22 a, 22 b adjacent the overlap portions 18 a, 18 b,respectively.

Preferably, the overlap portions 18 a, 18 b of the logs 16 a, 16 b havea geometrical configuration 20 a, 20 b, which is shaped so that theoverlap portions 18 a, 18 b of adjacent logs 16 a, 16 b fit together atthe corner 12 in an interlocking arrangement. The geometricalconfiguration 20 a, 20 b can include cut-outs as commonly provided insaddle-notch corners, butt-and-pass corners, and in dovetail cornerconstruction.

In the embodiment illustrated (FIGS. 2 and 3), the geometricalconfigurations 20 a, 20 b, comprise dovetails 21 a, 21 b milled into theoverlap portions 18 a, 18 b of the logs 16 a, 16 b. Each dovetail 21 hasa generally planer upper surface 23 and lower surface 25, both of whichare inclined to the horizontal. Generally vertical shoulder surfaces 27extend upward and downward from the upper and lower surfaces 23 and 25of the dovetail 21, respectively, along the non-overlapping portions 22of the logs 16. Each dovetail 21 also has a generally vertical side face29, extending between the upper and lower surfaces 23 and 25.

Referring again to FIG. 2, the mating surfaces of adjacent dovetails 21at the corner 12 define corner joint interfaces 24. More particularly,the upper and lower surfaces 23 and 25 of adjacent dovetails 21 liegenerally flush against each other defining generally horizontal(although inclined) corner joint interfaces. As well, the shouldersurfaces 27 lie generally flush against the side faces 29 of theadjacent dovetails 21, defining generally vertical corner jointinterfaces.

Referring now to FIGS. 2 and 4, the wall 14 a has a distinct wallsection 26 a in which the non-overlapping portions 22 a of the logs 16 aare vertically adjacent each other. Similarly, the wall 14 b has adistinct wall section 26 b in which the non-overlapping portions 22 b ofthe logs 16 b are vertically adjacent each other.

The area between the distinct wall sections 26 a and 26 b of theintersecting walls 14 a and 14 b is defined as the corner joint area 28.The corner joint area 28 is characterized as an area of the intersectingwalls 14 a and 14 b in which the overlapping portions 18 a and 18 b ofthe logs 16 a and 16 b overlap each other in an alternating, interlacedarrangement.

Referring to FIG. 5, the corner connection structure 10 is furtherprovided with a slot 30 that extends, in the horizontal, obliquelyacross the corner joint area 28 of the intersecting walls 14 a, 14 b.The slot 30 extends, in the vertical, along substantially the entireheight of the walls 14 a, 14 b at the corner 12.

As best seen in FIG. 6, vertically aligned grooves 32 a, 32 b areprovided in the logs 16 a, 16 b. The grooves 32 a, 32 b cooperate toform the slot 30 in the corner connection structure 10. Morespecifically, each log 16 a, 16 b is provided with a groove 32 a, 32 bthat extends vertically through the height of the log 16, and extendshorizontally in a direction which is oblique to the longitudinal axis ofthe log 16.

The particular angle between the grooves 32 a, 32 b and the horizontalaxis of the corresponding logs 16 a, 16 b can conveniently be selectedto be generally equal to each other. The slot 30 formed by thecooperating grooves 32 a, 32 b is thereby generally perpendicular to aline bisecting the included angle between the intersecting walls 14 aand 14 b. In the embodiment illustrated, the walls 14 a, 14 b intersectat 90°, and the grooves 32 a, 32 b are oriented at about 45° relative tothe corresponding longitudinal axes of the logs 16 a, 16 b.

Further details of the grooves 32 will now be described, with referenceto FIG. 7. Each groove 32 in the logs 16 has an open vertical edge 34positioned along the log 16 to abut the overlap portion 18. In otherwords, the log material on either side of the open vertical edge 34 ofthe groove 32 is part of the overlap portion 18 of the log 16. Thegroove 32 extends horizontally to a closed vertical edge 36, which ispositioned within the adjacent non-overlapping portion 22 of the log 16.

In logs 16 having overlap portions 18 with geometrical configurations20, the height of the log 16 will generally not be constant along thelength of the groove 32. For example, in the embodiment illustratedhaving dovetails 21, the height of the log 16 has a step at the shouldersurface 27. The intersection of the groove 32 and the shoulder surface27 defines a threshold 33 within the groove 32.

As best seen in FIG. 7, each groove 32 has an interstacking portion 35which extends within the overlap portion 18 of the log 16. In theembodiment illustrated, the interstacking portion 35 of the groove 32extends from the open vertical edge 34 to the threshold 33. Each groove32 also has a non-interstacking portion 37 extending within thenon-overlap portion 22 of the log 16. In the embodiment illustrated, thenon-interstacking portion 37 of the groove 32 extends from the threshold33 to the closed vertical edge 36.

The side surfaces of the groove extending between the open edge and theclosed edge define an outer side surface 38 facing towards the end 17 ofthe log 16 proximate the corner 12, and an inner side surface 40opposite the outer side surface 38.

As mentioned above, the grooves 32 of vertically adjacent logs 16 at thecorner 12 cooperate to form the slot 30. More specifically, the overlapportions 18 a of the logs 16 a of the first wall 14 a and the overlapportions 18 b of the logs 16 b of the second wall 14 b overlap eachother in an alternating, interlaced arrangement at the corner 12 (FIG.2). The interstacking portions 35 a and 35 b of the grooves 32 a and 32b therefore also overlap in an alternating fashion. The grooves 32 a and32 b are positioned in the logs 16 a and 16 b of the walls 14 a, 14 b,so that the outer side surfaces 38 a, 38 b of the grooves 32 a, 32 b ofvertically adjacent logs 16 a, 16 b are substantially coplanar,providing a generally continuous outer sidewall 42 of the slot 30 (FIGS.5 and 6). Similarly, the inner side surfaces 40 a, 40 b of the grooves32 a, 32 b of vertically adjacent logs 16 a, 16 b are in substantiallycoplanar alignment, forming a generally continuous inner sidewall 44 ofthe slot 30.

The non-interstacking portions 37 a, 37 b of the grooves 32 a, 32 bprovided in logs 16 a, 16 b do not overlap each other in an alternating,interlaced arrangement. The non-interstacking portions 37 a arevertically adjacent other non-interstacking portions 37 a, and thenon-interstacking portions 37 b of the grooves 32 b of logs 16 b arevertically adjacent other non-interstacking portions 37 b.

The open vertical edges 34 a of the grooves 32 a in the logs 16 agenerally adjoin the grooves 32 b where the grooves 32 b cut through theshoulder surfaces 27 b of adjacent logs 16 b. In other words, the openvertical edges 34 a of the grooves 32 a are vertically aligned with thethresholds 33 b of the grooves 32 b in the adjacent logs 16 b.Similarly, the open vertical edges 34 b of the grooves 32 b in the logs16 b generally adjoin the grooves 32 a where the grooves 32 a cutthrough the shoulder surfaces 27 a of the adjacent logs 16 a. Thisalignment of the grooves 32 a and 32 b forms the slot 30, extendingbetween generally continuous vertical edges 36 a and 36 b, and inner andouter sidewalls 44 and 42.

It is to be appreciated by one skilled in the art that logs used toconstruct log homes typically do not have a vertically symmetricalcross-sectional profile, but rather, the logs often have distinct uppersurface and lower surface profiles. Accordingly, the logs of the firstwall 14 a and the logs of the second wall 14 b have grooves 32 a, 32 bwhich are mirror image to each other, rather than identical to eachother. Further details of log profiles according to the presentinvention will be discussed subsequently.

As seen in FIG. 2 the corner connection structure 10 is further providedwith a spline 50, which is adapted to fit snugly in the slot 30.Referring to FIGS. 8, 9 a and 9 b, the spline 50 has a horizontal width52 which extends substantially all the way across the width of the slot30, between the opposed vertical edges 36 a and 36 b. The spline 50 hasa thickness 54 which is small enough to allow the spline 50 to beinserted in the slot 30, but is preferably large enough to provide upperand lower horizontal edge surfaces 56 which facilitate stacking of thesplines 50 upon one another in the slot 30. In the embodimentillustrated in FIG. 9 a, the spline 50 has a plate portion 58 thatextends between opposed vertical edges 57 and between upper and lowerhorizontal edges 56. The plate portion 58 of the spline 50 has athickness 54 which is slightly less than the space between the sidewalls44 and 42 of the slot 30, and a width 52 which is slightly less than thespace between the edges 36 a, 36 b of the slot 30.

The height 55 of the spine 50 can be any height which is convenient forthe assembly of the corner connection structure 10. As best seen in FIG.4, the stacked spines 50 extend almost the entire height of the walls 14a, 14 b at the corner 12. The upper edge 56 of the uppermost spline 50is spaced below the tops of the walls 14 a, 14 b to provide a settlinggap 49.

In the embodiment illustrated, a typical spine 50 is shown having aheight approximately equal to the height of the logs 16 a, 16 b used toconstruct the walls 14 a, 14 b. The stacking of the spines 50 producesseams 59 between the upper and lower horizontal edge surfaces 56 ofvertically adjacent spline 50.

The height 55 of the splines 50 in the corner connection structure neednot be uniform, and the height of some splines 50 can be increased toadvantageously reduce the number of splines 50, and hence the number ofseams 59 between adjacent splines 50, at the corner 12. Reducing thenumber seams 59 reduces the number of potential gaps through whichdrafts and moisture can pass.

The splines 50 can be constructed of any suitable material, such as, butnot limited to, steel, aluminum, or polymer material. The splines 50 mayadvantageously be cut to the desired height from a length of extrudedmaterial.

As each log 16 is laid down at the corner 12, a spline 50 is insertedinto the slot 30, and pressed snugly against the previously installedspline 50. This ensures that the grooves 32 a, 32 b are properly alignedto extend the slot 30 as successive logs 16 are installed, and alsoprovides stability of the logs 16 as the walls 14 a, 14 b are beingbuilt.

As best seen in FIG. 10, the spines 50 simultaneously block off thejoint interfaces 24 between the overlap portions 18 a, 18 b of theadjacent logs 16 a, 16 b of the corner 12. In particular, the generallyhorizontal joint interfaces between the upper and lower surfaces 23 and25 of adjacent dovetails 21, as well as the generally vertical jointinterfaces between the shoulder surfaces 27 and the adjacent side faces29 of adjacent dovetails 21 are sealed against weather intrusion by thespline 50. This advantageously eliminates the need for gaskets orcaulking between the mating joint interface surfaces 24 at the corner12.

To further enhance the weather-proofing characteristics of the cornerconnection structure 10, the vertical position of the seams 59 betweenvertically adjacent splines 50 can be adjusted so that the seams 59intersect with the joint interfaces 24 as few times as possible. In theembodiment illustrated, having geometrical configurations 20 comprisingdovetails 21, the seams 59 are positioned at approximately the verticalmidpoint of the dovetail 21 of any single log 16 a or 16 b.

Furthermore, a sealant 60 can be provided between the upper and loweredge surfaces 56 of adjacent splines 50 to enhance the weatherproofingcharacteristics of the corner connection structure 10. The sealant 60can be, for example, but not limited to, a strip of asphalt-impregnatedsealant tape.

Referring again to FIGS. 8, 9, and 10, the spline 50 can be providedwith a locking rib 62 having a thickness 64 which extends transverselyfrom the plate portion 58 of the spline 50. In the embodimentillustrated in FIG. 8 and 9, the rib thickness 64 extends from the outersurface of the spline, and the rib is oriented generally verticallyalong the outer surface of the spline, at about an equal distance fromthe opposed vertical side edges 57 of the plate portion 58 of the spline50.

The locking rib 62 enhances the corner connection structure 10 bypreventing horizontal movement of the logs relative to one another in adirection parallel to the plate portion 58 of the spline 50.Furthermore, the rib 62 provides a fixed point towards which the log 16will draw as it dries and shrinks over time. By providing a single pointtowards which the logs 16 in the walls 14 will shrink, a tighter,stronger joint is generated over time.

To accommodate the rib 62, the slot 30 is provided with a generallycontinuous rib recess 66 (FIG. 5). In the embodiment illustrated, therib recess 66 comprises a generally cylindrical bore 67 positionedadjacent the outer sidewall 42 of the slot 30. The cylindrical bore 67has a diameter tangentially intersected by the slot 30.

To form the rib recess 66, pockets 68 a, 68 b are provided along thegrooves 32 a, 32 b in the logs 16 a, 16 b (FIG. 6). The pockets 68 a, 68b overlap in alternating arrangement at corner 12, and are positioned tobe in vertical alignment, thereby forming the rib recess 66.

Referring to FIG. 8 a, the cross-sectional profile of the outer surfaceof the rib 62 can be shaped to cooperate with the inner surface of therib recess 66 so that areas of contact 70 between the rib 62 and the ribrecess 66 are interspersed with areas of non-contact 72. In theembodiment illustrated, the rib 62 has an outer surface which ispolygonal having a plurality of vertices 74, and the inner surface ofthe rib recess 66 is generally cylindrical. The vertices 74 of the outersurface of the rib 62 are sized to have a slight interference fit withthe inner surface of the rib recess 66. This provides good holdingcontact, while also reducing the chances of binding in the verticaldirection. This is considered advantageous because relative movementbetween the splines and the logs in the vertical direction is desirableto accommodate natural settling of the logs over time.

An alternative spline 80 is illustrated in FIG. 11. The spline 80 issimilar to the spline 50, having a plate portion 58 and a rib 62.However, in the spline 80, the plate portion 58 is comprised of twodistinct plate portion segments 82 and 84, each of which extendscontiguously in opposite directions from the rib 62. In the embodimentillustrated, a gap 86 separates the plate portion segments 82, 84, andthe gap 86 is positioned adjacent the rib 62.

Through-Bolt System

The corner connection structure 10 can further be provided with athrough-bolt clamping apparatus shown generally at 110 in FIGS. 1 and 4.The through-bolt clamping apparatus 110 has a through-bolt 112 thatextends generally vertically through the plurality of courses of logs 16forming the walls 14 a, 14 b.

In the embodiment illustrated in FIG. 4, the through-bolt 112 of thethrough-bolt clamping apparatus 110 extends through the corner jointarea 28 of the walls 14 a, 14 b at the corner 12. To accommodate thethrough-bolt 112, the spline 50 can be provided with a verticallyoriented bolt cavity 114 (FIG. 12). In cross section, the bolt cavitymay be enclosed by the spline itself, or by a combination of the splineand a sidewall of the slot.

As best seen in FIG. 13, in one embodiment the bolt cavity 114 isprovided within the rib 62 of the spline 50. The cross sectional area ofthe bolt cavity 114 is completely enclosed within the spline 50.Furthermore, in the embodiment illustrated, the bolt cavity 114 ispolygonal in cross section. More specifically, the bolt cavity 114 hasan inner surface 116 which is hexagonal in cross-section.

Referring again to FIG. 12, the through-bolt clamping apparatus 110 isprovided with transversely extending upper and lower clamp arms 120, 121(respectively), adjacent the upper and lower ends 118, 119 of thethrough-bolt 112. The upper and lower clamp arms 120, 121 are adapted tocouple the through-bolt 112 to the logs 16 at the upper and lower endsof the walls 14 a, 14 b, respectively.

In the embodiment illustrated, the lower clamp arm 121 of thethrough-bolt clamping apparatus 110 is part of an anchor spline assembly117 having an anchor plate 122 extending through a horizontal groove 124provided across the rib 62 of the lowermost spline 50 of the cornerconnection structure 10. The anchor plate 122 has a centrally locatedaperture 126, which is aligned with the bolt cavity 114 extendingthrough the spline 50.

A fastener 128 extends upward through the aperture 126, and engages anelongate hex-nut 130 which is provided within the bolt cavity 114,adjacent the top surface 132 of the anchor plate 122 . The outer surfaceof the hex-nut 130 is slightly smaller than the hexagonal inner surface116 of the bolt cavity 114, thereby permitting axial displacement of thehex-nut 130 within the bolt cavity 114, but inhibiting rotation of thehex-nut 130 when the threaded rod 112 is turned. Accordingly, ananti-rotate coupling device is provided which enables assembly andadjustment of the threaded rod 112 to the lower clamp arm 121 from theupper end of the walls 14 a, 14 b, without need to access thethrough-bolt apparatus 110 from the lower end of the walls 14 a, 14 b.

The fastener 128 passes through the aperture 126 in the anchor plate 122and is tightened securely, thereby producing the anchor spline assembly117. The length of the screw 128 and the length of the hex-nut 130 areselected so that an upper portion of the hex-nut 130 extendssufficiently beyond the upper end of the screw 128, thereby providingadequate engagement with a threaded portion 134 provided adjacent thelower end 119 of the through-bolt 112.

Referring to FIG. 14, a clamp arm recess 136 is provided in theunderside of the lowermost (starter) log 16 at the corner 12 of thewalls 14 a, 14 b, to accommodate the transversely extending anchor plate122. More specifically, the length and the width of the clamp arm recess136 are sized slightly larger than the length and the width of theanchor plate 122. The depth of the recess 136 provides an indentedhorizontal contact surface 138 for bearing the clamp load applied by thethrough-bolt clamping apparatus 110 on the anchor plate 122.

Once the intersecting walls 14 a, 14 b have been completely assembled,the threaded rod 112 of the through-bolt clamping apparatus 110 can beinserted through the bolt cavity 114 and rotated so that its lowerthreaded end 119 securely engages the elongate hex-nut 130. Suitablewashers 140 and a spline stacking nut 142 can then be installed andtightened along a threaded portion 143 provided adjacent the upper end118 of the through-bolt 112. The spline-stacking nut serves to draw thesplines 50 together, so that any seams 59 between vertically adjacentsplines 50 are substantially weather-tight. The washers 140 and thespline stacking nut 142 are sized so that collectively their outerdiameters are small enough to fit within the rib recess of the cornerconnection structure, but are large enough to provide a lower surfacewhich positively engages an upper surface 56 of the uppermost spline 50provided in the corner connections structure 10.

It is considered advantageous to avoid direct application of a clampload generated by the clamping apparatus 110 onto the corner joint area28, because the portions of the logs 16 at the corner joint area 28,namely the overlap portions 18, typically shrink more quickly than theadjoining, non-overlap portions 22. The increased rate of shrinkage canbe the result of proximity to the exposed ends 17 of the logs, andbecause the overlap portions 18, having geometrical configurations 20,have a reduced cross-sectional area relative to the adjoiningnon-overlapping portions 22.

Accordingly, the upper clamp arm 120 comprises a transfer bar 144coupled to the through-bolt 112 (FIG. 4). The transfer bar 144 isadapted to bridge the non-overlapping portions 26 a, 26 b of the firstand second walls 14 a, 14 b so that a clamping load generated by thethrough-bolt clamping apparatus 110 can be transferred directly to thenon-overlapping portions 26 a, 26 b rather than onto the corner jointarea 28.

More specifically, the transfer bar 144 has a body 146 and a pair ofspaced-apart contact pads 148 a and 148 b. The first contact pad 148 aengages the first wall 14 a at a position spaced away from the cornerjoint area 28, along the non-overlapping distinct wall section 26 a ofthe wall 14 a. The second contact pad 148 b engages the second wall 14 bat a position spaced away from the corner joint area 28, along thenon-overlapping distinct wall section 26 b of the wall 14 b.

Referring again to FIG. 12, the contact pads 148 a, 148 b of thetransfer bar 144 extend generally vertically from the transfer bar body146, which extends generally horizontally between the two contact pads.In the embodiment illustrated, the transfer bar 144 comprises a platehaving down-turned ends, resulting in an inverted U-shaped member.

The transfer bar 144 is provided with an aperture 150, which iscentrally located along the horizontally extending transfer bar body146. The threaded portion 143 of the upper end 118 of the through-bolt112 passes through the aperture 150, and a clamping nut 152 can beinstalled adjacent an upper surface 151 of the transfer bar, to applythe compressive load on the walls.

Preferably, as shown in the embodiment illustrated, a compression spring154 may be provided between the clamp nut 152 and the upper surface 151of the transfer bar 144. Spring seats 156 can be provided at the upperand lower ends of the compression spring 154, to ensure that the spring154 remains generally concentric about the through-bolt 112. Thecompression spring 154 can compensate for natural settling of the logs.

By spacing apart the contact pads 148 a, 148 b on the transfer bar 144,the downward compressive force on the walls passes through thenon-overlapping portions 22 a, 22 b of the logs 16 a, 16 b rather thanalong the overlap portions 18 a, 18 b, which have a reducedcross-sectional area resulting from the geometrical configurations 20provided therein. The present invention comprehends that the overlapportions 18 of the logs 16 may dry out more quickly, and may thereforeshrink faster and to a greater extent than the adjacent non-overlappingportions 22 of the logs.

Furthermore, the present invention comprehends that the logs 16 in thewalls 14 will settle over time, causing a corresponding decrease in theoverall height of the walls 14. As the uppermost surface of the walls 14shifts downwards due to settling, the spring 154 forces the transfer bar144 downwards, thereby maintaining a positive clamping force on thewalls 14. The settling gap 49, along with the additional clearanceprovided by downward extension of the contact pads 148 from the transferbar body 146, ensures that the transfer bar can be pushed downwardwithout interfering with the uppermost spline 50.

To assist in transferring the clamp load generated by the clampingapparatus 110 away from the corner joint area 28 and onto the adjoining,distinct wall sections 26 a, 26 b of the walls 14 a, 14 b, analternative anchor spline assembly 157 can be provided (FIG. 15). Theanchor spline assembly 157 has a lower clamp arm 121 comprising aninverted transfer bar 144.

More particularly, the anchor spline assembly 157 has a spline 50, anelongate hex nut 130, and a transfer bar 144. The transfer bar 144 isinverted, so that the contact pads 148 a, 148 b, are directed upwardly.A fastener 160 extends upwardly through the aperture 150 and engages thehex nut 130. The hex nut is then inserted in the lower end of the boltcavity 114 extending through the rib 62 of the spline 50. In theembodiment illustrated, the fastener 160 is a bolt welded to the body146 of the transfer bar 144.

To accommodate the transfer bar 144 of the anchor spline assembly 157, aclamp arm recess 162 is provided at the lower end of the corner jointarea 28 of the walls 14 a, 14 b at the corner 12. The clamp arm recess162 crosses the corner joint area 28, having recess portions 162 a and162 b in the logs 16 a and 16 b, respectively. Inner sidewalls 164extend generally vertically along the perimeter of the recess 162. Anassembly retaining screw 168, passing through an aperture 166, can beused to hold the anchor spline assembly 157 in position, prior toinstallation and tightening of the clamping apparatus 110.

In use, the contact pads 148 a, 148 b of the transfer bar 144 of theanchor spline assembly 157 engage the walls 14 a, 14 b along thedistinct wall sections 26 a, 26 b respectively. Accordingly, theclamping force applied by the clamping apparatus 110 is directed throughthe non-overlapping portions 22 a, 22 b of the logs 16 a, 16 b in thewalls 14 a, 14 b rather than through the overlap portions 18 a, 18 b.

Furthermore, the mating hex profiles of the bolt cavity 114 and hex nut130, along with the retaining screw 168 and inner sidewalls 164 providean anti-rotate coupling arrangement between the transfer bar 144 and thetrough-bolt 112.

Referring now to the FIG. 17, the through-bolt apparatus 110 can beprovided not only adjacent the corner 12, but also along the wall 14between corners 12. A through-bolt cavity 170 extends through the logs16 of the wall 14 to accommodate the through-bolt 112.

The through-bolt clamping apparatus 110 can be provided with ananti-rotate anchoring device 172 coupled to the lower end 119 of thethrough-bolt 112. In one embodiment (FIG. 18), the anchoring device 172comprises an anchoring sleeve 174 and the lower clamp arm 121. The lowerclamp arm 121 can be a pin 176 adapted to fit in a generally horizontalbore 178 passing through the anchoring sleeve 174. The pin 176 is longerthan the width of the sleeve 174, so that ends 177 of the pin 176 extendbeyond the outer surface of the sleeve 174.

A generally horizontal locking bore 180 is provided in the lowermost(starter) log 16 of the wall 14. The locking bore 180 intersects thethrough-bolt cavity 170 adjacent the bottom of the wall 14, and isadapted to receive the pin 176.

In use, the sleeve 174 of the anchoring device 172 is inserted into thethrough-bolt cavity 170 of the lowermost log 16 of the wall 14. Thesleeve 174 is positioned so that the bore 178 of the sleeve 174 isaligned with the locking bore 180 of the log 16. The pin 176 is theninserted into the locking bore 180 and pushed through the bore 178 ofthe sleeve 174. A plug 181 can be inserted into the exposed end of thebore 180 for concealment.

The engagement of the ends 177 of the pin 176 with the inner surface ofthe locking bore 180 of the log 16 provides a bearing surface for theclamp load applied by the clamping apparatus 110, and also provides ananti-rotate coupling arrangement of the pin 176 to the lower end 119 ofthe through-bolt 112.

More particularly, the sleeve 174 is provided with an internallythreaded vertical engagement bore 182, having a tapered lead surface184. The lower end 119 of the through-bolt 112 can be lowered into thethrough-bolt cavity 170 from above, and guided into the engagement bore182 by the tapered lead surface 184. The through-bolt 112 can then berotated to securely engage the sleeve 174.

An alternative anchoring device 186 can be used in place of anchoringdevice 172. Referring to the FIGS. 20 and 21, the alternative anchoringdevice 186 comprises an inverted transfer bar 144 as its lower clamp arm121. The fastener 160 extending from the transfer bar 144 is coupled toa generally vertical internally threaded bore 190 provided in an anchorsleeve 188. The upper end of the bore 190 of the anchor sleeve 188 isprovided with a tapered lead surface 192, similar to the surface 184 ofthe sleeve 174.

To accommodate the transfer bar 144, a clamp arm recess 194 is providedin the underside of the lowermost log 16 of the wall 14. A retainingfastener 168 can be provided through an aperture 166 in the transfer bar144 to retain the anchoring device 186 within the recess 194 in the log16. The inner sidewalls of the recess 194, along with the retainingfastener 168, prevent rotation of the transfer bar 144, therebypermitting installation and adjustment of the through-bolt 112 from theupper end of the wall 14, without the need for a second person to holdtight the anchoring device 186.

Log Profile

A log profile according to the applicant's teaching is referenced in thefigures generally by character 210. The log profile 210 may be providedin the log 16 used to construct walls 14 of, for example, but notlimited to, a cabin or house.

Referring to FIG. 22, the profile 210 of the log 16 provides a topsurface 212, a bottom surface 214, an inner side surface 216, and anouter side surface 218. The inner side surface 216 is a generally planervertical surface, extending between upper and lower inner edges 220,222, respectively. The outer side surface 218 is similarly a generallyplaner vertical surface, which extends between upper and lower outeredges 224, 226, respectively.

The top surface 212 of the profile 210 extends between the inner andouter upper edges 220 and 224. The top surface 212 has two verticallyupwardly projecting tongues 230, each having inner and outer inclinedsidewalls 232 and 234, respectively. In the embodiment illustrated, theouter sidewall 234 is double-inclined, having a steeper inclined upperportion 234 a, and a less steeply inclined lower portion 234 b. Thetongues 230 have generally horizontal upper faces 236 extending betweenthe inner and outer sidewalls 232, 234 of the tongues 230.

The profile 210 further comprises a channel 238 extending between theinner side surfaces 232, 232 of the tongues 230. A v-groove 240 isprovided in the channel 238, extending along the longitudinal axis ofthe log 16.

The bottom surface 214 of the profile 210 extends between the inner andouter lower edges 222 and 226. The bottom surface 214 has two upwardlydirected engagement grooves 242 adapted to receive the tongues 230 ofthe top surface 212 of an adjacent log 16. Each groove 242 has inner andouter inclined sidewalls 244, 246, respectively. In the embodimentillustrated, the outer sidewall 246 is double-inclined, having a moresteeply inclined upper portion 246 a, and a less steeply inclined lowerportion 246 b. Each groove 242 has a generally horizontal base 248extending between the inner and outer inclined sidewalls 244 and 246.

A seal recess 250 can be provided in the base 248 of the grooves 242. Inthe embodiment illustrated, the seal recess 250 is positioned in thebase 248 of each groove 242, immediately adjacent the outer inclinedsidewall 246.

The profile 210 of the log 16 further provides a plateau surface 252extending between the inner sidewalls 244 of the grooves 242. A v-groove254 is provided in the plateau 252, extending along the longitudinalaxis of the log 16.

The bottom surface 214 of the log 16 is also provided with reflexivelyinclined margin surfaces 256 adjacent the inner and outer side surfaces216 and 218. More specifically, one margin surface 256 extends betweenthe lower inner edge 222 of the log 16 and the outer sidewall 246 of theadjacent groove 242. Similarly, a second margin surface 256 extendsbetween the lower outer edge 226 of the log 16 and the outer sidewall246 of the adjacent groove 242.

In use (FIG. 23), the top surface 212 and the bottom surface 214 ofvertically adjacent logs 16 interlock with each other to provideaccurate stacked alignment of the logs in the wall 14. Moreparticularly, the tongues 230 of the top surface 212 of one log 16engage the grooves 242 of the bottom surface 214 of another log 16positioned immediately above the first log. The slopes of the inclinedtongue sidewalls 232, 234 match the slopes of the corresponding groovesidewalls 244, 246 so that they are in flush contact with each other.This contact assists in positively locating the logs relative to eachother, and provides lateral stability of the wall 14 in a directionperpendicular to the axes of the logs 16.

Furthermore, the upper faces 236 of the tongues 230 contact the basesurfaces 248 of the grooves 242, to provide positive verticalpositioning of one log 16 relative to another.

The staggered seam created by the adjacent top and bottom surfaces 212,214 provided by the log profile 210 also assists in keeping out theweather. To further improve the weather proofing characteristics of theinterface between the upper surface 212 and the lower surface 214 ofadjacent logs 16, sealant 258 is provided in the seal recess 250 of thebottom surface 214. The sealant 258 can be, for example, but not limitedto, asphalt-impregnated sealant tape. Preferably, the sealant 258 iscompressed by the assembly of one log 16 on top of another, to enhancethe sealing action of the sealant 258.

The location of the sealant 258 along the interface between the topsurface 212 and bottom surface 214 of adjacent logs 16 is alsoinstrumental in blocking out moisture. Specifically, with referenceagain to FIG. 23, the sealant 258 is located along the base 248 of thegroove 242 immediately adjacent the interface between the inclinedsidewalls 234 and 246 of the tongue 230 and groove 242, respectively.Accordingly, the sidewall 234 presents an upwards slope towards anymoisture attempting to enter the interface between the adjacent logs 16,from the exposed side surface 218, 216. The force of gravity is therebyused to inhibit the penetration of moisture through the interface.

Furthermore, the distal portion of the interface between the logs 16that extends from the outside face 218 to the seal 258 has no horizontalsurfaces. The sloping nature of the interface along that portion of thecross-section of the logs inhibits the collection of water between thelogs.

Advantages of the double inclined outer sidewalls 234 of the tongue 236and the margin surface 256 are also best seen in FIG. 23. In particular,the double inclined sidewall 234 increases the cross sectional area ofmaterial of the log 16 between the tongue 230 and the outside face 218of the log 16. This strengthens the lower outer portions of the logs 16,and resists any lateral outward force exerted by the stacked weight ofthe logs. As well, the double inclined sidewall 234 and the marginsurface 256 provide a blunter point 260 at the bottom of the log 16,which may be less susceptible to damage during transport and handling ofthe logs 16.

The interaction of the v-grooves 240 and 254 provided in the top surface212 and bottom surface 214 of the logs 16 can also best be seen in FIG.23. Specifically, the opposed v-grooves 240 and 254 co-operate to forman aperture 262 between vertically adjacent logs 16 in the wall 14. Theaperture 262 can serve a number of uses, some of which will be discussedhereinafter.

Referring now to FIG. 24, an alternative profile 270 for the logs 16 hasa modified top surface 272 extending between the inner and outer upperedges 220 and 224, and a modified bottom surface extending between theinner and outer lower edges 232 and 226 of the log 16.

The top surface 272 has a pair of upwardly extending tongues 276, eachhaving inner and outer inclined sidewalls 278, 280, respectively. Eachtongue 276 has a top face 284 extending between the inner and outersidewalls 278, 280. A step-shaped seal recess 286 is provided in the topface 284 of each tongue 276, immediately adjacent the outer sidewall280.

The bottom surface 274 of the log profile 270 has a pair of grooves 288,each having inner and outer inclined sidewalls 290 and 292,respectively. Each groove 288 has a base 293 extending between the innerand outer sidewalls 290, 292.

In the alternative profile 270, the slopes of the inclined tonguesidewalls 278, 280 do not match the corresponding groove sidewalls 290,292 (FIG. 25). More specifically, in the embodiment illustrated, theouter sidewalls 292 of the grooves 288 are sloped more steeply than theouter sidewalls 280 of the tongues 276. As well, the inner sidewalls 278of the tongues 276 are sloped more steeply than the inner sidewalls 290of the grooves 288.

Accordingly, when one log 16 is placed on top of another log 16 in thewall 14, the tongues 276 of the top surface 272 engage the grooves 288of the bottom surface 274 of the adjacent log 16. However, the sidewalls278, 280 of the tongues 276 are not in flush contact with the sidewalls290, 292 of the grooves. Rather, cavities 294 are provided between thesidewalls 280 and 292. Similarly, cavities 296 are provided between thesidewalls 278 and 290.

The cavities 294 cooperate with the seal recess 286 to accommodate thesealant 258. The cavities 296 can accommodate additional sealant 258 tofurther enhance the weather-proofing characteristics of the loginterface and to provide lateral stability for alignment of the logs.When the top surface 272 and the bottom surface 274 of two adjacent logs16 engage each other, the sealant 258 in the cavities 294 and 296 iscompressed and squeezed downward within the cavities 294, 296 intowedge-shaped seal elements. This fills a portion of the space betweenthe opposed vertically inclined sidewalls, thereby locating thecorresponding logs in horizontal alignment with each other. Moreover,the vertically adjacent logs can shrink and expand independently withoutcompromising the weather-proofing characteristics of the sealedinterface, since the resilient sealant 258 can expand and contract toaccommodate any difference in the rates of expansion or contraction ofthe logs 16. In addition, the sealant 258 is positioned away from thecenter of the log where apertures for plumbing, electrical wiring, orthrough-bolts are typically provided. Accordingly, the sealant 258 inthe embodiment illustrated can extend without interruption along thelength of the walls 14, and problems related to squeeze-out of sealantentering such apertures are eliminated.

Wall Support Structure

A support structure according to one example of the applicant's teachingis shown generally in the Figures at reference character 310. Referringto FIG. 1, the support structure 310 is provided adjacent an opening 312in the wall 14. The opening 312 may be provided in the wall 14 for avariety of reasons, such as, for example, but not limited to,accommodating a window, door, or fireplace.

Referring now to FIG. 26, the opening 312 extends between vertical sidesurfaces 314 and upper and lower horizontal surfaces 316 a, 316 b,respectively, extending along the logs 16 forming the wall 14. Thevertical side surfaces 314 are also referred to herein as edge surfaces314 of the wall 14. The upper and lower horizontal surfaces 316 a, 316 bare also referred to herein as header and sill surfaces 316 a, 316 b,respectively. In milled log packages, the vertical side surfaces 314 ofthe opening 312 may be precut, providing end faces 318 along either sidesurface 314 of the opening 312. Typically, these precut end faces 318are only provided for logs whose full cross sectional height abuts thesides 314 of the opening 312. If the height of the opening 312 must beextended partially across the height of adjacent logs, the builder canmake vertical extension cuts 320 in logs which run adjacent the upper orlower sides 316 of the opening 312. In such cases the log materialextending between the extension cuts 320 of opposing side surfaces 314must also be removed, thereby producing the horizontal surfaces 316 ofthe opening 312.

Referring now to FIG. 27, in openings 312 having a full cross-sectionallog 16 extending along the lower horizontal surface 316, support blocks322, 324 can be provided along the top surface 212 of the log 16 havinga profile 210, to square off the lower surface 316 of the opening 312.In particular, and with reference to FIG. 28 a, the support blocks 322each have an inclined base 326 in flush contact with the inclinedsidewalls 234 of the tongues 230. A generally horizontal support surface328 is provided opposite the base 326. Referring to FIG. 28 b, thesupport block 324 is generally rectangular in cross-section, having abase 330 in flush contact with the channel 238 between the tongues 230of the log 16 having the profile 210. A generally horizontal supportsurface 332 is provided opposite the base 330 of the support block 324.

Referring to FIGS. 26 and 29, the support structure 310 comprisesconnectors 336 positioned within the wall 14 adjacent the opening 312.The connectors 336 have a connector body with lower and upper logengagement portions 338, 340. In the embodiment illustrated, theconnectors 336 comprise dowel pins which are vertically oriented in thewall 14. The lower engagement portion 338 engages a log in one course ofthe wall, and the upper engagement portion 340 engages the logimmediately above the log engaged by the lower log engagement portion338.

The number of connectors 336 provided along each vertical side 314 ofthe opening 312 is such that each log 16 having a fully exposed end face318, has a connector 336 extending from both the upper and lowersurfaces of the log (FIG. 26). Accordingly, the lowermost logs havingend faces 318 adjacent the opening 312 are connected to the log below,which spans the opening 312. Similarly, the uppermost logs 16 having endfaces 318 adjacent the opening 312 are connected to the log above, whichspans the openings 312. The connectors 336 thereby serve to strengthenthe wall 14 at the opening 312, and to align and support the logs as thewall is being built.

As best seen in FIG. 30, the logs 16 are provided with upper and lowerconnector apertures 342, 344, respectively, adapted to receive the lowerand upper log engagement portions 338, 340 of the connectors 336. Theupper and lower connector apertures 342, 344 extend into the top andbottom surfaces 212, 214 of adjacent logs 16, and can comprise upper andlower portions of apertures 346 extending through the height of the logs16 adjacent the opening 312 in the wall 14.

The apertures 342, 344 are generally centrally located across thecross-sectional width of the logs 16. More specifically, the apertures342, 344 intersect the v-grooves 240, 254 provided in the top and bottomsurfaces 212, 214 of the logs 16. Along the length of the logs 16, theapertures 342, 344 are spaced away from the end faces 318 of the logs16, so that an axial load bearing portion 348 of the log 16 is providedbetween the apertures 342, 344 and the end faces 318 (FIG. 31).

Referring now to FIG. 31, the cross-sectional profile of the outersurface of the connector 336 can be shaped to cooperate with the innersurface of the apertures 342, 344 so that areas of contact 350 betweenthe connector 336 and the apertures 342, 344 are interspersed with areasof non-contact 352. In the embodiment illustrated, the connector body ishexagonal and the apertures 342, 344 are cylindrical. The vertices ofthe outer surface of the connector 336 are sized to have a slightinterference fit with the apertures 342, 344. This provides good holdingcontact, while also accommodating some degree of misalignment betweenthe apertures 342, 344 provided in vertically adjacent logs 16.

Referring again to FIG. 26, the opening support structure 310 furthercomprises a sub-jamb member (or framing member) 360 having respectiveupper and lower ends 360 a and 360 b, and positioned along each verticalside surface 314 of the opening 312. The sub-jamb members 360 do notextend the full height of the opening 312, but rather, a settling gap362 is provided between the upper horizontal surface 316 (i.e. theheader surface 316 a) of the opening 312 and the upper end 360 a of thesub-jamb members 360. Typically, this gap would be about 1.5 inches, toaccommodate natural settling of the logs over time.

As best seen in FIG. 32, each sub-jamb 360 has inner and outer verticalstruts 364, 366 aligned with the inner and outer faces 216, 218(respectively) of the logs 16. Each strut 364, 366 is provided with avertical groove 368, the openings of which face each other in horizontaland vertical alignment. The grooves 368 cooperate to receive a centralpanel 370. The struts 364, 366 are also provided with verticallyextending seal recesses 372 along the surface of the struts 364, 366which lie adjacent the vertical side surfaces 314 of the opening 312.Vertically elongate slots 374 are provided in the central panel 370 ofthe sub-jamb 360.

To install the sub-jamb member 360 of the opening support structure 310,fasteners 376 are provided. The fasteners 376 couple the sub-jamb member360 to the connectors 336.

More specifically, with reference again to a preferred embodimentillustrated in FIG. 29, the fasteners 376 can comprise bolts having anexternal threaded portion 378 at one end, and a bolt head 379 at theopposite end. The bolts 376 extend through the slots 374 of the sub-jambmember 360, with the threaded portion 378 directed into the verticalside surface 314 of the opening 312. Washers 380 can be inserted betweenthe sub-jamb 360 and the heads 379 of the bolts 376.

Fastener access passageways 382 are provided in the logs 16 toaccommodate the bolts 376. The fastener access passageways 382 extendbetween the connectors 336 and the vertical side surfaces 314 of theopening 312. In the embodiment illustrated, the aperture 262 created bythe opposed v-grooves 240, 254 in the logs 16 provides the fasteneraccess passageways 382.

The connectors 336 are provided with fastener coupling means 384, forcoupling the fasteners 376 to the connectors 336. In the embodimentillustrated, the fastener coupling means 384 comprises an internallythreaded bore 385 extending horizontally through the connector body, ata position between the first and second log engagement portions 338,340. The internally threaded bore 385 is adapted to engage the threadedportion 378 of the bolt 376.

The connectors 336 can be further provided with an alignment pin 386extending generally horizontally beyond the body of the connector 336.The alignment pin 386 can engage an alignment surface 388 on an adjacentlog, to assist in aligning the fastener coupling means 384 with thefastener access passageway 382. In the embodiment illustrated, thealignment pin 386 is positioned below and in parallel alignment with theinternally threaded bore 385. The converging portion of the v-groove 240provided in the upper surface 212 of the logs 16 provides the alignmentsurface 388.

Having aligned the internally threaded bores 385 with the fasteneraccess passageways 382, the threaded portions 378 of the bolts 376 canengage the internally threaded bores 385 upon insertion through thepassageways 382. The bolts 376 can then be tightened to draw thesub-jamb 360 snugly against the vertical side surfaces 314 of theopening 312.

Upon initial installation, prior to any settling, the relative positionof the bolts 376 along the length of the slots 374 is such that a space390 is provided between the lower edge 392 of the slot 374 and the bolt376 (FIG. 34). The space 390, along with the settling gap 362 (FIG. 26),accommodate a reduction in the height of the opening 312 which naturallyoccurs as the logs 16 settle over time. In particular, the bolts canshift downwards within the slots 374, towards the lower edges 392 of theslots 374. Similarly, the upper horizontal surface 316 of the opening312 can shift downwards towards the upper edges of the sub-jamb members360.

This ability to accommodate settling of the logs 16 reduces oreliminates the high stress loads which would otherwise be transmittedonto the sub-jamb members 360 as the logs 16 settled over time.Accordingly, the sub-jamb members 360 provide attachment surfaces towhich structural elements of a window or door can be fastened, withoutrisk of distortion or damage to the window or door.

Furthermore, by coupling the sub-jamb members 360 to the connectors 336,reliable mounting of the sub-jamb members 360 is realized. Inparticular, the retaining force that holds the sub-jamb members 360 inplace is applied across the load-bearing portion 348 of the logs 16(FIG. 31). This is in contrast to simply embedding a fastener in the endgrain of the logs 16 through the exposed end faces 318. Fastenersembedded in log end grain are susceptible to loosening as the fibers ofthe wood can easily spread apart.

Exterior Side Casing Structure

An exterior side casing structure according to an example of theapplicant's teaching is shown generally in FIG. 1 at reference character410. The side casing structure 410 is provided on the outside of thewall 14 around the perimeter of the opening 312.

Referring to FIG. 34, the casing structure 410 comprises vertical casingmembers 412 extending along the outer side surfaces 218 of the logs 16,at a position adjacent a framing member such as the sub-jamb members 360of the opening support structure 310.

Referring to FIG. 35, the vertical casing members 412 can be generallyrectangular in cross-section, having a front face 414, a rear face 416,and inner and outer side surfaces 418 and 420, respectively. The rearface 416 has a mounting surface 422 adjacent the inner side surface 418.A channel 424 is provided in the rear face 416 adjacent the outer sidesurface 420.

Between the channel 424 and the mounting surface 422 of the rear face416, a seal recess 426 is provided. A sealant 428 (FIG. 36) can beprovided in the seal recess 426. The sealant 428 can be, for example,but not limited to, asphalt-impregnated sealant tape.

Referring to FIG. 36, the vertical casing members 412 are mountedadjacent the opening 312 by securing the mounting surface 422 of therear face 416 to the sub-jamb member 360. In particular, the mountingsurface 422 of casing member 412 is seated against an outside edgesurface 367 of the sub-jamb member 360. Suitable adhesive or fastenerscan be used to attach the casing member 412 to the sub-jamb 360. In theembodiment illustrated, finishing nails 430 are used to attach thecasing member 412 to the sub-jamb 360.

As best seen in FIG. 36, the channel 424 spans the seams 432 between thesub-jamb 360 and the end faces 318, 320 of the logs 16 adjacent theopening 312. This provides drainage and ventilation for any moisturewhich may penetrate the area behind the casing members 412 and the seams432.

To enhance the drainage of any moisture behind the casing members 412,drainage troughs 434 can be provided in the lower horizontal surface 316of the opening 312, directly below the seams 432 and adjacent thechannel 424 of the casing member 412. In the embodiment illustrated, thedrainage troughs 434 comprise grooves having an inclined base 436, anopen upper edge 438 facing the lower end of the sub-jamb 360, and anopen front edge 440 facing the channel 424 of the casing member 412.

Butt Joint Connection Structure

A butt joint connection structure according to an example of theapplicant's teaching is shown generally in FIG. 1 at reference character510. The butt joint connection structure 510 is provided betweenadjacent end faces of any two logs 16 comprising the walls 14 so thatthe logs 16 may be joined together end-to-end.

Referring now to FIG. 37, the butt joint connection structure 510 isillustrated in combination with two logs 512 and 514 of the logs 16forming the wall 14. The logs 512, 514 have end faces 516, 518,respectively, (not shown), which are in flush contact with each otherforming a seam 520 between the logs 512, 514.

The butt joint connection structure 510 comprises a butt spline 522 andfasteners 524. The butt spline 522 is adapted to be received in agenerally vertical spline slot 526 which spans the seam 520 between theadjacent end faces 516, 518 of the logs 512, 514. In the embodimentillustrated, the butt spline slot 526 extends horizontally in adirection which is substantially parallel to the common longitudinalaxes of the logs 512, 514.

To form the butt spline slot 526, spline grooves 528, 530 are providedin the end faces 516, 518 of the logs 512, 514, respectively (FIG. 38).Each butt spline groove 528, 530 has an open vertical edge 532 providedin the end face 516, 518 and an opposed closed vertical edge 534opposite the open vertical edge 532. Opposed butt spline groove innerand outer side faces 536, 538 extend between the open and closedvertical edges 532, 534.

The butt spline grooves 528 and 530 in the logs 512 and 514 arepositioned so that the open vertical edges 532 align to face each other.The inner side faces 536 of the grooves 528 and 530 cooperate to form agenerally continuous inner sidewall 540 of the butt spline slot 526.Similarly, the outer side faces of the grooves 528 and 530 cooperate toform a generally continuous outer sidewall 542 of the butt spline slot526 (FIG. 37).

Referring now to FIG. 39, the butt spline 522 is generally rectangularin cross-section, being adapted to fit snugly in the butt spline slot526. The butt spline 522 has a thickness 546 which fits between theopposed inner and outer sidewalls 540, 542 of the slot 526, and a width548 which fits between the opposed closed vertical edges 534 of the slot526. The butt spline 522 has an inner face 550 in flush contact with theinner sidewall 540 of the slot 526, and an opposed outer face 552 inflush contact with the outer sidewall 542 of the slot 526. The height ofthe butt spline 522 extends substantially along the cross-sectionalheight of the logs 512, 514. The butt spline 522 can be constructed ofwood, polymer, or any other suitable material.

The butt spline 522 is provided with vertically extending fastenerrecesses 554 that are adapted to cooperate with the fasteners 524 forsecuring the butt joint connection structure 510. In the embodimentillustrated, two recesses 554 are provided along the inner face 550 ofthe spline 522. The recesses 554 are generally semi-circular incross-section, providing a recess opening 556 in the plane of the innerface 550 of the spline 522. Furthermore, lateral catch surfaces 558 areprovided along the inner surface of the recesses 554, extending inwardlyfrom either edge of the recess openings 556. The catch surfaces 558 ofthe recesses 554 interact with the fasteners 524 to secure the buttjoint connection structure 510, as will be described subsequently.

The two recesses 554 are spaced apart so that one recess is on eitherside of the seam 520 between the logs 512, 514. In other words, therecess opening 556 of one recess 554 abuts the inner side face 536 ofthe groove 528 provided in the log 512. The recess opening 556 of thesecond recess 554 abuts the inner side face 536 of the groove 530provided in the log 514.

The interaction of the fasteners 524 and the recesses 554 will now bedescribed. Referring to FIG. 40, the recesses 554 and the inner faces536 of the grooves 528, 530 cooperate to provide apertures 560 forreceiving the fasteners 524. The apertures 560 provide a cross-sectionalarea which is significantly less than the cross-sectional area of thefasteners 524. More particularly, in the embodiment illustrated, thefasteners 524 comprise spikes having a shaft 562 of generally circularcross-section (FIG. 37). The radius of the semi-circular recesses 554 isabout equal to the radius of the circular shaft 562 of the spikes 524.Accordingly, the cross-sectional area of the apertures 560 is only abouthalf that of the cross-sectional area of the shaft 562 of the spikes524.

As a result, the spikes 524 must be forced into the semi-circularapertures 560 for assembly of the butt joint connection structure 510.This generates a significant lateral force, pressing the outer face 552of the spline 522 against the outer side faces 538 of the grooves 528,530. This force impedes any relative movement between the spline 522 andthe logs 512, 514, thereby securing the butt joint connection structure510.

Furthermore, forcing the spikes 524 into the apertures 560 can createdepressions 564 (shown in phantom in FIG. 40) in the logs 512, 514,opposite the recesses 554 provided in the spline 522. The depressions564 have log catch surfaces 566 which extend into the inner side faces536 of the grooves 528, 530. By forming the depressions 564 uponinsertion of the spikes 524 into the apertures 560, the log catchsurfaces 566 are necessarily aligned with the opposing spline catchsurfaces 558 of the recesses 554.

Accordingly, the shaft 562 of the spikes 524 engages the catch surfaces558 and 566 formed along the inner surfaces of the apertures 560, andthereby prevent any horizontal movement of the spline 522 relative tothe logs 512, 514. In other words, by extending transversely across theinterface between the spline 522 and the grooves 528, 530, and byengaging the respective transverse catch surfaces 558, 566, the shaft562 of the spikes 524 locks the logs 512 and 514 together.

Referring again to FIG. 37, the butt joint connection structure 510 canfurther comprise seal assemblies 570. The seal assemblies 570 areadapted to be received in seal slots 572, which span the seam 520between the adjacent end faces 516, 518, of the logs 512, 514.

In the embodiment illustrated, two seal slots 572 are provided in thebutt joint connection structure 510. More specifically, one seal slot572 is provided between the spline slot 526 and the inner side surface216 of the logs 512, 514, and another seal slot 572 is provided betweenthe spline slot 526 and the outer side surface 218 of the logs 512, 514.The seal slots extend vertically along the cross-sectional height of thelogs 512, 514, and extend horizontally in a direction generally parallelto the common axis of the logs 512, 514.

Referring again to FIG. 38, each seal slot 572 is formed of opposed sealgrooves 574 and 576 provided along the end faces 516 and 518 of the logs512, 514 respectively. Each seal groove has an end wall 578 and opposedside surfaces 580 and 582 extending between the end wall 578 and the endface 516, 518. The side surfaces 580, 582 of the grooves 574 are inalignment with the side surfaces 580, 582 of the grooves 576, therebyforming the generally continuous seal slots 572 extending between theend walls 578.

Referring again to FIG. 37, the seal assemblies 570 comprise stiffeningbars 584 which are affixed to a sealing element 586. The sealing elementis preferably compressible, and may be, for example, but not limited to,asphalt-impregnated sealant tape. The stiffening bars can be ofgenerally rectangular cross-section, and may be constructed of, forexample, but not limited to, wood or plastic.

In the embodiment illustrated, the seal assemblies 570 comprise twostiffening bars 584 provided on opposite sides of the sealing element586. Each stiffening bar 584 has an inner face 588 adjacent the sealingelement 586, and an outer face 590 in contact with an end wall 578 ofthe seal slot 572. The stiffening bars 584 and the sealing element 586have a height which is generally equal to the cross-sectional height ofthe logs 512, 514.

In the relaxed, unassembled state, the seal assemblies 570 have athickness which fits snugly within the distance between the opposed sidesurfaces 580 and 582 of the seal slots 572, and the seal assemblies havea width which exceeds the distance between the opposed end walls 578 ofthe seal slots 572. Accordingly, to insert the seal assembly into theseal slot 572, the two stiffening bars 584 must be pressed together,thereby compressing the sealing element 586. The seal assembly may thenbe pressed into the seal slot 572, by applying force on the upper endsof the stiffening bars 584. The stiffening bars facilitate properplacement of the sealing element 586 along the height of the logs 512,514, by preventing the sealing element 586 from folding or crumplingupon insertion into the seal slots 572.

As best seen in FIGS. 37 and 41, the butt joint connection structure 510can be provided with horizontal seals 592 and 594, to further enhancethe weather-proofing characteristics of the butt joint 510. The seals592, 594 can be, for example, but not limited to, asphalt-impregnatedtape.

The seals 592 are provided adjacent the upper and lower edges of thebutt spline 522. Accordingly, as best seen in FIG. 41, the upper andlower seals 592 are compressed between the upper end of the spline 522and the plateau surface 252 of the log above the spline 522, and thelower end of the spline 522 and the channel surface 238 of the log belowthe spline 522.

The seals 594 are provided adjacent the upper ends of the sealassemblies 570. The horizontal position of the seal assemblies 570 alongthe cross sectional width of the logs 16 can be advantageously alignedwith the sealant 258 provided in the recesses 250 in the logs 16 (FIG.41). Accordingly, the seals 594 are compressed between the upper ends ofthe seal assemblies 570 and the adjacent sealant 258. The lower end ofeach seal assembly 570 bears directly against the adjacent sealant 258.Additional seals 594 could be provided between the lower ends of theseal assemblies 570 and the adjacent sealant 258.

As seen in FIG. 41, the apertures 262 advantageously provide clearancebetween vertically adjacent logs to accommodate the head of the fastener524.

Post-to-Log Connection Structure

A connection structure according to an example of the applicant'steaching is shown generally at 610 in FIG. 42. The connection structure610 has a generally vertical post 612 to which horizontal logs 16 of awall 14 can be attached. The use of vertical posts 612 can provide amethod of connecting intersecting walls 14, and can provide supportpoints along a wall 14 and can advantageously reduce the required lengthof the logs 16.

The post 612 has a generally vertical joint face 614 which is shaped toengage end faces 616 of the logs 16 in substantially flush contact. Inthe embodiment illustrated, the joint face 614 and end faces 616 areplanar surfaces oriented generally vertically (the end faces 616defining an edge surface of wall 14), but other configurations couldalso be provided. Furthermore, in the embodiment illustrated, thevertical post 612 is generally square in cross-section, and a singlejoint face 614 for connection to logs 16 has been illustrated. The post612 could have any one of a variety of cross-sectional profiles,including, for example, but not limited to, hexagonal or octagonal. Thepost 612 would generally be provided with at least two joint faces 614.

The connection structure 610 further comprises a link assembly 620 forcoupling the logs 16 to the post 612. The link assembly 620 comprises apost-engaging clamp bracket 622, a log-engaging connector 624, and afastener 626 extending between the bracket 622 and connector 624.

As best seen in FIG. 43, in the embodiment illustrated, the fastener 626is a socket head cap screw. An elongate hex nut 628 is threaded onto theend of the fastener 626. A lock pin 630 is provided transversely througha distal end of the nut 628, for purposes which will be describedhereinafter. The lock pin 630 can be press fit into a corresponding bore629 provided through the nut 628.

The clamp bracket 622 has lateral clamp arm ends 631 which extend beyondthe profile of the hex nut 628. In the embodiment illustrated, the clamparm ends 631 comprise horizontally outer portions of a pair of flanges632 a, 632 b, which are connected along a leading edge 634 to form av-shaped profile. In the link assembly 620, the leading edge 634 of thebracket 622 is directed towards the connector 624. The bracket 622 hasan aperture 636 which is generally centrally located, and intersects theleading edge 634. The aperture 636 is sized to allow passage androtation of the hex nut 628 within the aperture 636.

The connector 624 has upper and lower log engagement portions 638, 640,respectively, which are adapted to engage vertically adjacent logs 16 inthe wall 14. In the embodiment illustrated, the connector 624 is avertically oriented dowel pin of hexagonal cross-sectional profile. Theconnector 624 also has a horizontal bore 642 positioned between theupper and lower log engagement portions 638, 640, which is adapted toreceive the fastener 626. More specifically, the bore 642 is sized topermit sliding passage of the shaft of the fastener 626, and iscounter-bored opposite the bracket 622 to provide a recessed fit for thehead of the fastener 626 (FIG. 42).

The post 612 is provided with a channel 646 extending along the jointface 614. The channel 646 has a bracket housing portion 648 shaped toreceive the bracket 622, and a slot portion 650 extending between thebracket housing portion 648 and the joint face 614. The bracket housingportion 648 is provided with oblique retaining shoulders 652 a, 652 bwhich are shaped and positioned to engage the flanges 632 a, 632 b ofthe bracket 622. More specifically, the retaining shoulders 652 a, 652 bin the embodiment illustrated extend outwardly from either side of theslot portion 650 of the channel 646, and away from the joint face 614(FIG. 44).

The logs 16 are provided with upper and lower connector apertures 662,664, which are the same as the connector apertures 342, 344, provided inthe opening support structure 310 of the present invention. The upperand lower connector apertures 662, 664 in vertically adjacent logs 16are shaped to receive the lower and upper log engagement portions 640,638, respectively, of the connector 624.

In use, the post 612 is positioned adjacent a log 16, so that the jointface 614 of the post 612 is in flush contact with the end face 616 ofthe log 16.

The bracket 622 of the link assembly 620 can then be aligned with, andslidingly inserted into, the bracket housing portion 648 of the channel646 in the post 612. The link assembly 620 is lowered to a point wherethe connector 624 contacts the log 16. The connector 624 can then bealigned with the aperture 662 by orienting the connector 624 to thevertical and adjusting the fastener 626 as may be required to obtain thecorrect spacing between the bracket 622 and the connector 624. Duringthe alignment process, the lock pin 630 passing through the nut 628 canbe advantageously seated within the converging flanges 632 a, 632 b toprovide an anti-rotate coupling arrangement of the nut 628 and thefastener 626.

Once aligned, the connector 624 can be tapped or pressed into place, sothat the lower log engagement portion 640 of the connector 624 engagesthe upper connector aperture 662 in the log 16. The lowermost installedposition of the connector 624 is achieved when the shank of the fastener626 bottoms out in the v-groove 240 provided along the top surface ofthe log 16.

Once the connector 624 has been installed, the fastener 626 can betightened to draw the post 612 and the log 16 snugly together. Inparticular, with reference to FIG. 44, tightening the fastener 626 drawsthe clamp bracket 622 towards the connector 624. Accordingly, theflanges 632 a, 632 b of the bracket 622 bear against the retainingshoulders 652 a, 652 b, of the channel 646. This provides a reliableconnection and also serves to horizontally align the log 16 and the post612, due to the oblique angle at which the retaining shoulders 652 andflanges 632 are provided.

After tightening the fastener 626, the next log 16 may be laid down,ensuring that the lower connector aperture 664 in the lower surface ofthe next log is aligned with and engages the upper log engagementportion 638 of the connector 624.

Accordingly, the connection structure 610 provides a secure joint whichstabilizes the logs horizontally in a direction perpendicular to theaxis of the logs 16, but also draws the logs 16 snugly against the post612. Moreover, the bracket 622 can shift in a vertical directionrelative to the post 612, allowing the post-to-log connection structure610 to accommodate natural settling of the logs 16 relative to the post612 over time.

The connection structure 610 can further be provided with a sealassembly 570, as provided in the butt joint connection structure 510. Inthe embodiment illustrated, two seal slots 672 are provided, each sealslot 672 being shaped to receive a seal assembly 570.

Each seal slot 672 spans the seam between the joint face 614 of the post612, and the end face 616 of the log 16. The seal slots 672 are similarto the seal slots 572, being formed of opposed seal grooves 674 and 676provided along the joint face 614 of the post 612 and the end face 616of the log 16, respectively. As for the butt joint connection structure510, the seal assemblies 570 may be inserted into seal slots 672 of thepost-to-log connection structure 610 by pressing the stiffening bars 584together, so that the sealing element 586 is compressed. The sealassembly 570 may then be inserted into the slot 672 by applying adownward force to the upper ends of the stiffener bars 584.

Referring to FIG. 45, an alternative seal assembly 670 is illustrated.The seal assembly 670 may be used as an alternative to the seal assembly570 in either of the butt joint connection structure 510 or post-to-logconnection structure 610 of the present invention.

The seal assembly 670 is provided with a pair of opposed stiffener bars684, but rather than having a single sealing element 586 extendingbetween the bars 684, two separate sealing elements 686 a and 686 b areprovided. Each of the sealing elements 686 a, 686 b are affixed to onlyone stiffener bar 684. Accordingly, the seal assembly 670 comprises twoseal sub-assemblies 670 a and 670 b.

The seal assembly 670 can advantageously be used in cases where thegrooves 574 and 576, or 674 and 676, are not in precise alignment witheach other (FIG. 46). The slots 572, 672 so formed can have an offsetalong the seams which they span. Accordingly, one seal sub-assembly 670a, 670 b can be squeezed into each groove 574, 674 or 576, 676 such thatthe sealing portions 686 a, 686 b abut each other at the seam, andimproved weather-proofing can thereby be provided.

While preferred embodiments of the invention have been described hereinin detail, it is to be understood that this description is by way ofexample only, and is not intended to be limiting. The full scope of theinvention is to be determined from reference to the appended claims.

1. A connection structure for a log wall, comprising: a) a plurality oflogs extending horizontally in an axial direction and stacked verticallyto form a wall, the logs each having an end face at one end thereof, theend faces of the logs being generally vertically aligned with each otherand defining an edge surface of the wall; b) a post having a generallyvertical joint face abutting the end faces of the logs; c) a pluralityof connectors retained within the wall adjacent the edge surface of thewall; d) a plurality of fastener access passageways in the wall, eachfastener access passageway extending between a respective one of theconnectors and the post; and e) a plurality of fasteners, each fastenerextending through a respective one of the fastener access passagewaysand having a first end coupled to a respective one of the connectors anda second end coupled to the post, and wherein the connectors extendbetween vertically adjacent pairs of the plurality of logs, each pair oflogs including a respective lower log and an upper log generallysituated on top of the lower log, each connector having a connector bodywith a lower and an upper log engagement portion, each lower logengagement portion engaging the respective lower log, and each upper logengagement portion engaging the respective upper log.
 2. The connectionstructure of claim 1 wherein each respective lower log comprises a topsurface and each respective upper log comprises a bottom surfacegenerally facing the top surface of each respective lower log, each topsurface having an upper connector aperture extending therefrom and intothe respective lower log for receiving the lower log engagement portionof the respective connector, and each bottom surface having a lowerconnector aperture extending therefrom and into the respective upper logfor receiving the upper log engagement portion of the respectiveconnector.
 3. The connection structure of claim 2, wherein each of thefastener access passageways comprises a depression in at least one ofthe top surface of the respective lower log and the bottom surface ofthe respective upper log, the at least one depression extending from arespective one of the connector apertures to a respective one of the endfaces of the logs.
 4. The connection structure of claim 1 wherein eachconnector is spaced axially apart from the end faces to provide a loadbearing portion of each respective log between the connectors and theend faces.
 5. The connection structure of claim 4 comprising a pluralityof brackets, each bracket coupled to the post and to a respectivefastener adjacent the second end thereof, the fastener being adjustableto securely draw together the logs and the post.
 6. The connectionstructure of claim 5 wherein the post comprises a bracket-retainingchannel in the joint face of the post, the channel extending verticallyalong the height of the post.
 7. The connection structure of claim 6wherein each of the brackets is vertically slidable within the channeland fixed against rotation relative to the post.
 8. The connectionstructure of claim 6 wherein the channel comprises a bracket housingportion spaced axially away from the joint face and a slot portionextending between the joint face and the bracket housing portion, eachbracket being slidably retained in the bracket housing portion and eachfastener extending through the slot portion.
 9. The connection structureof claim 8 wherein the bracket housing portion comprises shouldersextending laterally outward from the slot portion, and the bracketincludes laterally extending clamp arms that bear against the shoulders.10. The connection structure of claim 1, wherein each of the fastenersextending between the respective first and second ends thereof isoriented generally parallel to the axial direction of the logs.
 11. Theconnection structure of claim 1, wherein each connector comprises atransverse bore generally intermediate the respective lower and upperlog engagement portions, the transverse bore aligned with a respectivefastener for coupling the respective connector to the respectivefastener.
 12. A connection structure for a log wall, comprising: a) aplurality of horizontally extending, vertically stacked logs forming awall, the logs defining an axial direction along their lengths, the logseach having an end face at one end thereof, the end faces of the logsbeing generally vertically aligned with each other; b) a post having agenerally vertical joint face in abutment with the end faces of thelogs; c) at least one link assembly for coupling at least one of thelogs to the post, each link assembly including a connector anchored inthe at least one log and a bracket anchored in the post and coupled tothe connector, the bracket being vertically slidable relative to thepost, and wherein the link assembly comprises a fastener extendingbetween the bracket and the connector; and, d) a channel in the jointface of the post, the channel extending vertically along the height ofthe post, wherein the bracket is vertically slidable within the channel,and wherein the channel comprises a bracket housing portion spacedaxially away from the joint face and a slot portion extending betweenthe joint face and the bracket housing portion, the bracket housingportion having a greater lateral extent than the slot portion whenviewed from above, the bracket being slidably retained in the brackethousing portion and the fastener extending through the slot portion. 13.The connection structure of claim 12 wherein the housing portioncomprises shoulders extending laterally outward from the slot portion,and the bracket includes laterally extending clamp arms that bearagainst the shoulders.
 14. The connection structure of claim 12, whereinthe fastener comprises a bolt having a first end coupled to theconnector and a second end opposite the first end and coupled to thebracket.
 15. The connection structure of claim 14 wherein the connecterhas a cross bore extending generally horizontally through the connectorand through which the fastener extends, the cross bore having acounter-bored portion directed away from the bracket, the head of thebolt being seated in the counter-bored portion.
 16. The connectionstructure of claim 14 wherein the link assembly comprises a threadedmember coupled to the bracket for engaging the threaded portion of thebolt, the threaded member being fixed against rotation relative to thebracket, and the bracket being fixed against rotation relative to thepost.
 17. The connection structure of claim 12, wherein the bracketcomprises a leading edge that at least partially invades the slotportion of the channel.
 18. The connection structure of claim 12,wherein the bracket and connector are axially retained between a bracketengagement surface and a connector engagement surface each extendingradially outwardly of the fastener adjacent opposing ends of thefastener, and wherein the link assembly is adjustable for adjusting thespacing between the bracket engagement surface and the connectorengagement surface.
 19. A connection structure for a log wall,comprising: a) a plurality of horizontally extending, vertically stackedlogs forming a wall, the logs defining an axial direction along theirlengths, the logs having generally vertically aligned end faces at oneend thereof; b) a post having a generally vertical joint face inabutment with the end faces of the logs; c) a plurality of connectorspositioned in the wall adjacent the post, each connector having aconnector body with a lower and an upper log engagement portion, eachlower log engagement portion engaging a respective lower log in thewall, and each upper log engagement portion engaging a respective upperlog in the wall, each upper log being positioned vertically above eachlower log, respectively; d) a plurality of clamp brackets retainedwithin the post, each clamp bracket generally positioned in horizontalregistration with a respective connector; and e) a plurality offasteners, each fastener extending between a respective connector andbracket for coupling together the respective connector and clampbracket, the clamp brackets and connectors cooperating upon adjustmentof the respective fasteners to exert an axial clamp force on portions ofthe logs and post positioned axially between the respective clampbrackets and connectors; wherein the fasteners are vertically slidablerelative to the post within the clamp brackets coupled thereto foraccommodating settling of the logs over time.